Blade Design and Manufacturing

Philipp Haselbach: The lecture intends on introducing you to the design and manufacturing of wind turbine blade structures.
In the lecture Blade Design and Manufacturing you will learn how a typical design procedure of a wind turbine blade structure looks. During the lecture, the iterative design process from the idea to the final product is demonstrated. Moreover, the lecture focuses on the manufacturing process, where the different steps from the design of the moulds to the layup, vacuum infusion process, and curing procedure will be explained as well as the final assembly of a wind turbine blade is illustrated.

[@WindmillsTech]

🌬 Key Takeaways 🌬 🔧 Design Procedure: The design starts with parameters like rotor diameter, height, and rated power. External conditions such as wind speed and loads are considered for a good structural design. 💨 External Conditions: Wind turbine design depends on site-specific inputs, including wind classes and turbulence classes. Reference wind speed and maximum wind speed are crucial factors in determining the design. ✈ Aerodynamic Design: The blade's aerodynamic shape is optimized to create lift while minimizing drag. Airfoil thickness varies along the span of the blade, ensuring structural strength and efficiency. 📏 Structural Design: The structural design focuses on creating a lightweight yet sturdy blade. Layup, material distribution, and layering techniques are crucial for withstanding loads and ensuring durability. ⚙ Aeroelastic Design: Aerodynamic and structural designs are iteratively refined to account for loads and optimize the controller's efficiency. Simulations and testing are conducted to validate the design. 🔬 Verification and Testing: Numerical simulations and finite element analysis are performed to validate the design methodology. Strain, stress, tip deflection, and buckling are analyzed to ensure blade integrity. 🔩 Manufacturing Process: The manufacturing process involves creating a mold, packing blade components, and performing the vacuum infusion process. High-precision measurements and inspections are conducted. 🔍 Inspection and Adjustments: Mold geometry is scanned, and adjustments or repairs are made to meet design specifications. Ply sequences, cutting angles, and root inserts are carefully considered during packing. 🌪 Vacuum Infusion Process: The preform stack of fabrics, foam, and inserts is infused with resin using vacuum and resin distribution media. Proper resin flow and curing ensure a quality composite. 🔥 Curing and Assembly: The infused blade is cured using controlled heating. Components are adhesively bonded together, and the blade is trimmed. Geometry checks are performed before final product completion. nice comprehensive overview of blade design and manufacturing. Thanks Professor Philipp for a great video.